Electro-Chemical Honing of Gears — A new Method of Gear Finishing

The authors foresee that a productive high accuracy long tool life gear finishing method can be developed on ECH principle. Experiments show an accuracy in profile of 0.01mm. Crowning in tooth width can easily be obtained by photo-electric control of D.C. supply, while surface finish is a little bit better than honing. Machining time for a hardened gear of m=3.25, z=32, B=40 mm is about 6 minutes, stock removal 0.06mm over chord. Research works are made in three respects: (1) The ability of correcting geometric error in ECH of gears, its principle and methods of improving. (2) Dynamic behavior of dual-flank meshing process in ECH of gears. (3) False tooth profile derived from dual-flank meshing process, its theorectical analysis and methods of preventing.